Apparatus for detecting breaks during molten fiber formation



Aug- 23, 1966 F. N. STEPHENS E1I'Al. 3,258,314

APPARATUS FOR DETECTING BREAKS DURING MOLTEN FIBER FORMATION Y INVENTUM.ZA 2y@ 26 Jaseph E. Mcfv'ae l 4/ BY F/de/m /V, 57206605 Aus 23, 1966 F.N. STEPHENS `ETAL. I 3,268,314

APPARATUS FOR DETECTING BREAKS DURING MOLTEN FIBER FORMATION 2Sheets-Sheet 2 Filed Aug. 30, 1963 mw... k .w www M T c mgm W 0J ,QM Kfmv H m m% IIN v Nm III/RJ Y IN I 6% v@ Nxwswd www \I=|I. mm @AE @A QQ Q IQI N ml I United States Patent O 3,268,314 APPARATUS FR DETEQTING BREAKSDURING MOLTEN FIBER FURMAI'IGN Frederick N. Stephens, Leawood, Kans.,and Joseph R.

McBride, West Peabody, Mass., assignors to Gustin- Bacon ManufacturingCompany, Kansas City, Mo., a corporation of Delaware Filed Aug. 30,1963, Ser. No. 305,665 2 Claims. (Cl. 155-11) This invention relates toapparatus and process improvement in the detection and control ofbreakage in glass fibers being drawn from glass furnace bushings andrefers more particularly to such methods and apparatus wherein, once abreak is detected, suitable apparatus is moved to deflect the glasscoming from the bushing away from the winding drum normally operative todraw said glass fibers from said bushing.

The Patent to Case 2,955,772, issued October ll, 1960, for Textile FiberWinder illustrates a typical device for high speed winding of textilefibers on a rotating winding drum. In such an operation, strands oftextile glass fibers are formed by pulling some 204 glass fibers from aplatinum bushing. The fibers are collected together on a shoe to form astrand, at which point sizing is applied and, from the shoe, the strandis directed to a windup mechanism. The requirements for winding such atextile glass fiber strand dier markedly from those encountered -inWinding twisted fibers such as yarn. For textile fibers, it isimperative for one to be able to unwind individual strands Ifrom thedrum, each strand being made up of 204 filaments. The individualfilaments which make up the strand are not twisted together andtherefore have no unitary integrity. The `sizing serves to bind the 204filaments into a strand, but must not bind strands together so as tohinder the unwinding operation.

It is not uncommon for one or more fibers or filaments to break in thestrand winding process. In such case, the position of the filament withrespect to the bushing is critical. In case the break occurs in thefilament being pulled from one lof the end bushing orifices, the windingprocess can continue for a minute or so, although the glass may beaddown from the orifice of the broken filament. If the break occurs in acenter filament, the situation is more critical with the probability ofthe beading down broken filament seizing other monofilaments muchhigher. In such case, the process must be stopped and restarted with afresh filament -being drawn from the critical orifice.

Generally speaking, no fiber packages are saved which lhave been woundfor a period -of less than two minutes.

The causes of a fiber or filament bre-ak generally relate to anunbalenced temperature condition of the bushing. Thus, for example, ifthe bushing is too hot, the glass viscosity may be so reduced that agreater mass liow of glass occurs than is desired. Such quantity of flowmay exceed the ability of the drawing process to attenuate the fiber andsurface tension may be lost. Secondly, the difficulty may relate back tothe characteristics of the glass marbles fed to the furnace feedingbushing, particularly in the case where the refractory furnace producingthe glass for the marbles has spalled, thus producing stones or seeds inthe glass marbles. Likewise, if the marbles do not anneal properly,stresses may remain in the marble which may cause rupturing when heated.Further, the glass must be homogeneous in the melt tank with only asingle type of marble supplied else corded glass may be generated.Finally, humidity and temperature in the vicinity of the drawing processare critical and sudden changes in temperature are very undesirable.

The fiber or filament may break at the orifice in the l-CC bushing, atthe applicator roll or pad for sizing, on the heater wire or Reese roll.Occasionally, the cardboard winding tube or even the collet itself willexplode, thus causing breaks.

In commercial production, one man will generally handle six to tentextile fiber Winders of the type contemplated in the Case patent,supra, each fed by a separate platinum bushing. An optimum packageproduced by any one of these machines would be one which wound for tenminutes. If a Ibreak occurs at one or more machines while he is in theprocess of changing apackage on anothermachine, the operator mustimmediately, in the conventional setup, go to the device with the breakand move the hay chute into place to defiect the glass from the machinewith the break and shut off the motor driving the rotating collet.Unless this is done, the break can ruin a package. If, for example, anine-minute package were Wound, followed by a break, without theoperator stopping the drawing process and defiecting the glass from thepackage, it is possible that the beading down glass could mage aweldment on the package and thus cause the loss of the entire nineminute package.

Additionally, production information in winding operations -as tooperator and machine variance is difiicult to obtain. The poundageproduced is the only index to date.

An object of the invention is to provide means operable to detect glassfiber breaks as soon as possible by locating any glass Ibeadingoccurring at the bushing.

Another object of the invention is to provide a sensor for glass fiberbreaks which is completely out of the way of the glass drawing operationand does not hinder in any way the operator or the operation itself.

Another object of the invention is to provide an automatic activationmechanism for the hay chute and shutoff of the fiber winding collet oncea fiber break is detected whereby to give the operator as much time asdesired to get to the machine, remove the package and restart thewinding process.

Another object of the invention is to provide a signal in addition tothe action of the hay chute and shutdown, per se, which calls theattention of the operator to the down machine.

Another object of the invention is to provide means and techniquesoperable to increase production' and minimize lost operating time andmaintenance time in textile fiber winding rooms.

Another object of the invention is to provide mea-ns and techniquesoperable to enable better production evaluation information to begathered in textile fiber winding rooms and processes.

Another object of the invention is to provide means and devices whichoperate to maximize production in fiber Winder operations and alsomaximize protection of partial packages already wound.

Another object of the invention is to provide a sensing system ofvariable sensitivity to simultaneously warn and take care of fiberbreaks in fiber Winding operations.

Another object of the invention is to provide sensing systems which willdiscriminate between critical and noncritical fiber or filament breaksin winding systems.

Another object of the invention is to provide a ber break warning systemfor textile fiber w-inding operations which will effectively operatewith any type of bushing, fin cooled or not.

Other and further objects of the invention will appear in the course ofthe following description thereof.

In the drawings, which comprise a part of the instant specification andare to be read in conjunction therewith, an embodiment of the inventionis shown and, in the various views, like numerals are employed toindicate like parts.

FIG. 1 is a front view of an arrangement including the iiber drawingapparatus, per se, shown schematically, including the bushing, show andwinding drum, the hay chute and apparatus associated therewith formoving same into operative position from an inoperative position, thesensor which registers glass ber breaks at the bushing and a warninglight signal. The full line showing is with the hay chute in inoperativeposition and the dotted line is in operative position.

FIG. 2 is a view taken along the iine 2 2 of FIG. 1 in the direction ofthe arrows.

FIG. 3 is a side sectional view of the photo-electric cell receivingunit shown in FIGS. 1 and 2.

FIG. 4 is a schematic electrical diagram of the circuit used in theinstant arrangement and apparatus.

At is shown a ceiling structure which supports the furnace and feedingmeans therefrom for molten glass (not seen as conventional) which passesthe glass into conventional bushing 11 which may be of the types shownin the patents to Phillips 2,632,278 and Stephens et al. 2,846,1257.Bushing 11 has a number of small orifices 11a from which individualiibers 12 are drawn. Fibers 12 are drawn together in a shoe 13 fromwhence they are Wound as a strand 14 on drum 15 mounted on shaft 16. TheWinding drum mechanism and strand beating devices usually associatedtherewith are not detailed as they are conventional and typical or suchmechanisms as are disclosed in full detail in various patents previouslymentioned in this application,

A bracket 17 is fastened to ceiling 10 by bolts 18 and mounts verticalsleeve 19 which pivotally receives therein elongate shaft 20. Shaft 20has elongate :arm 21 fixed thereby by base 22 extending normal thereto.Attached to the free end of arm 21 is conventional hay chute 23 whichcomprises an elongate angled chute lioor having side walls 24 extendingvertically therefrom. Floor 45 is angled at approximately 45 fromvertical. Suitable clamps or attaching means 25 connect the outer end21a of arm 21 to the underside of the hay chute 23. Vertical handle 26is iixed to the free end of member 21a.

Vertical beam 27 has bracket 2S at the lower end thereof to which isconnected by pin 29 one end of hydraulic cylinder 30. The outer end ofhydraulic cylinder 30 is pivotally'connected by pin 31 to bracket 32,the latter connected to the upper side of arm 21.

The full line showing of the hay chute mechanism in the views shows samein inoperative position, that is, out of the line of draw of fibers 12from oriiices 11a of bushing 11. The dotted line position of the viewsshows the hay chute in operative position under bushing 11 deflectingsaid fibers 12 away from winding drum 15 (and into any suitable bin orcontainer (not seen)]. From FIG. 2 it can be seen that arm 21 pivotssomewhat less than 90 from inoperative to operative position withhydraulic cylinder piston 30a fully extended when hay chute 23 is in berdeecting position. It should be noted that the operator can optionallymove the hay chute into operative position by simple grasping handle 26and moving the hay chute into operating position. He also may move haychute 23 back out of operative position by manipulation of handle 26.The hydraulic line connections to hydraulic cylinder 30 are not shown asthey are conventional.

The sensing device for detecting incandescent beading of glass atorifices 11a is generally designated 33 and is received between upperand lower plates 34 and 3S of a mounting bracket, said plates heldtogether by bolts 36. Legs 37 mount the isensor bracket construction onceiling 10. Cable 38 carries signals from the sensor to the electricalsystem activating hydraulic cylinder 30 and the Warning signal. Anotherbeam 39 carries a socket 40 for an electric light 41 at t-he lower endthereof. This elec-' tric light is activated by signals from sensor 33at the same time hydraulic cylinder 30 is activated to move hay chute 23from inoperative to operative position.

Referring to FIG. 3, therein is shown the photo-electricV cell receiverunit for incandescent bead detection at thek bushing 11. This has beenpreviously generally designated 33 and comprises an elongate tube 50having recessed shelves 50a and 50b produced along the length thereofand opposed to one another by greater thickness portion 50c. Shelf 50areceives insert 51 having slot 51a in the end thereof, member 51retained Within tube 50 by removable screw 52. Tube insert 53 has slot53a in the end thereof abutting shelf 50h and carries lens 54 at theother end thereof retained thereagainst by retaining ring 55. Endenclosure tube 56 itself has recessed shelf portions 56a and 561;produced by greater thickness portion 56e. Hollow ring insert 57 havingopening 57a centrally thereof receives therewithin in greater diameterportion 57b thereof, rod 58 which is hollow centrally to receive thereinphoto-electric cell 59. Screws 60 mount thereon insulator 61 carryingcentrally thereof screw 62 having nut 63 thereon. Screws 60 are threadedthrough ring 57. End insert 64, by means of grommet 65 receives thecable 38 therein. Electrical communication from photo-cell 59 passes toscrew 62 and thence to cable 3S via wire 66. Ground wire 67 connectsfrom cell 59 to tube 56 and thence to ground.

Referring to FIG. 4, therein is shown 4a schematic circuit diagram ofthe electrical circuit used in the instant invention. 11S-volt A.C.power is input to lines 68 and 69. Disconnect switch 70 is normallyclosed. Fuse 71 is provided on line 68. Lines 72 and 73 input power totransformer generally designated 74. Plate circuit relay winding 75a isadapted to energize through its contact 7517 power control relay winding76a which energizes through its contact 76b hay chute solenoid 77(itself adapted to actuate the hydraulic cylinder 3G) and red warninglight 41. At 78 is seen the take-off for the filament of thyratron 79.Transformer output lines 80 and 81 lead to a D.C. source circuitcomprising bridge rectifier S2 connected through filtering capacitors 83and 84, filter inductor 85, fixed dropping resistor 86 and voltageregulator 87 to a voltage divider circuit generally designated 88. Oneside of the voltage divider circuit through lines 89 and 90 connectsphoto-conductive cell 59 between the D.C. source and the No. 1 grid ofthyratron 79. The No. 1 grid of the thyratron is then connected via line91 through fixed resistor 92 to ground 93. The other side of the cathodeand the No. 2 grid of the thyratron are connected by line 94 to thecenter tap of a potentiometer 95 which is connected between the D.C.source and the ground. Line 96 connects the other end of the voltagedivider circuit to the plate of thyratron 79 through auxiliary contact97 on the starter of the winding machine and plate circuit relay winding7 5a.

The detector is mounted near the bushing which is generatin-g theiilaments in a position to see all the filaments just as they come outof the bushing. When one or more filaments break, a bead of glass isformed which is seen by the detector and causes the hay chute and thered warning liquid to be activated. The detector consists of a tube witha slot in the end nearest the bushing, a photoconductive cell mounted inthe other end and a lens to focus the light from the slot on thesensitive area of the photo-conductive cell. When the light intensity ischanged on the photo cell, a resistance chan-ge Iacross the cel-loccurs. As the light intensity increases, the photo cell resistancedecreases, and the voltage on the thyratron grid increases. The detectorcircuit is powered by a regulated and filtered D.C. supply. v

The photo cell is connected between a D.C. source and the No. 1 grid ofa thyratron. The grid of the thyratron is then connected through a iixedresistor to ground. By using a voltage divider circuit the No. l grid iskept at a fixed D.C. potential when the lglass is drawing fibersproperly. The cathode and the No. 2 grid of the thyratron are connectedto the center tap of a potentiometer (sensitivity adjustment) which isconnected between the D.C. source and ground. By adjusting thepotentiometer, a Small bi Aifi applied to the thyratron to keep it fromtiring.

aaesla If the detector photo cell resistance decreases, the No. 1 gridvoltage is raised :and the thyratron starts conducting. Usually a singlebead is sufiicient to start the thyratron conducting. Starting thethyratron to conduct energizes a relay 75 or lCR in the plate circuitwhich initiates a relay sequence 76 or 2GB that energizes the hay chutesolenoid and the red light warning light system.

The detector circuit is set up by an auxiliary contact on the starter ofthe winding machine. After the bead is detected, the winding machine isshut down to rethread, at which time the detector circuit isautomatically reset (through the auxiliary contact shown on schematic).

From the foregoing it will be seen that this invention is one welladapted to attain all of the ends and objects hereinabove set forthtogether with other advantages which are obvious and which are inherentto the process.

It will be understood that certain features and subcombinations are ofutility and may be employed without reference to other features andsubcombinations. This is contemplated by and is within the scope of theclaims.

As many possible embodiments may be made of the invention withoutdeparting from the scope thereof, it is to be understood that all matterherein set forth or shown in the accompanying drawings is to beinterpreted as illustrative and not in a limiting sense.

Having thus described our invention, we claim:

1. Apparatus for protecting a ber winding operation wherein amultiplicity of fibers of molten material are drawn from a lmulti-oricedbushing and wound on a revolving drum comprising a photoelectricreceiver located at such point as to sense the light intensity at thebushing,

and signal when one or more incandescent beads are formed at the bushingwhen one yor more bers drawn therefrom are broken, a fiber deiiectingdevice positioned near and below said bushing, and means for removingsaid ber deecting device between the bushing and the winding drum onsaid signal from said photoelectric receiver.

2. Apparatus for protecting a fiber winding operation wherein amultiplicity of fibers of molten material are drawn from a multi-oricedbushing and Wound on a revolving drum comprising a photoelectricreceiver located at such point as to sense the light intensity at thebushing of a limted number of the fibers being drawn from said oriiicesin the ber drawing operation and signal when one `or more incandescentbeads are formed at the bushing when one or more of said limited numberof bers drawn therefrom are broken, a ber deflecting device positionednear and below said bushing, and means for moving said ber deiiectingdevice between the bushing and the winding drum on said signal from saidphotoelectric receiver.

References Cited by the Examiner UNITED STATES PATENTS 2,704,430 3/ 1955Harris 57-81 3,001,438 9/1961 Warthen 88-148 3,158,852 l1/l964 Schacher57-81 S. LEON BASHORE, Primary Examiner.

DONALL H. SYLVESTER, Examiner.

G. R. MEYERS, Assistant Examiner.

1. APPARATUS FOR PROTECTING A FIBER WINDING OPERATION WHEREIN AMULTIPLICITY OF FIBERS OF MOLTEN MATERIAL ARE DRAWN FROM AMULTI-ORIFICED BUSHING AND WOUND ON A REVOLVING DRUM COMPRISING APHOTOLECTRIC RECEIVER LOCATED AT SUCH POINT AS TO SENSE THE LIGHTINTENSITY AT THE BUSHING, AND SIGNAL WHEN ONE OR MORE INCANDESCENT BEADSARE FORMED AT THE BUSHING WHEN ONE OR MORE BIBERS DRAWN THEREFROM AREBROKEN, A FIBER DEFLECTING DEVICE POSITIONED NEAR AND BELOW SAIDBUSHING, AND MEANS FOR REMOVING SAID FIBER DEFLECTING DEVICE BETWEEN THEBUSHING AND THE WINDING DRUM ON SAID SIGNAL FROM SAID PHOTOELECTRICRECEIVER.